Scale-up and commercialization of an innovative forming technology for low-cost production of super-light automotive structural parts (SECA)

Transport is the largest greenhouse emitting sector in the UK. It accounted for 27% of total emissions in 2019\. Of this, the majority (91%) was produced by road vehicles. Vehicle weight is a main factor responsible for the large emissions. Emissions of new cars in the UK fell by only 1% between 2011 and 2019 due to the rising popularity of heavy weight SUVs which consume 25% more energy on average than medium-sized passenger cars. The growth of UK electric vehicle (EV) market also faces a challenge in the need to increase driving range, which is closely linked to vehicle weight. Thus, the impetus to save vehicle weight is now a key focus of the UK carmakers to meet the country's net zero target by 2050\.

Use of lightweight aluminium extrusion profiles is a promising solution to reduce vehicle body weight. Aluminium extrusion-intensive body structures enable 30% weight loss and 54% stiffness enhancement compared with steel counterparts (AEC, 2019). The reduced weight contributes to 5% drop in greenhouse emissions throughout a vehicle's full life cycle. However, aluminium extrusion profiles have yet to be fully exploited for passenger vehicles due to high product and assembly costs.

Integrating streamlined aluminium extrusion profiles in vehicle body structures makes it possible to reduce part numbers and assembly costs while improving profile dimensional precision and aerodynamic performance. However, streamlined aluminium extrusion profiles are still difficult to produce cheaply by conventional extrusion processes. Currently, streamlined aluminium extrusions are made from straight lengths of extruded profile which are then bent or cut and welded. Bending distorts the extruded cross-section and cutting/welding reduces the mechanical properties of an alloy, so both operations reduce stiffness and load bearing capacity of a designed structure. Additionally, the multi-step operation increases energy consumption, reduces productivity and adds cost to the manufacturing process.

This project consortium is seeking Innovate UK funding to exploit a UK-invented novel extrusion technology (Flextrude) to enable affordable manufacture of lightweight streamlined aluminium extrusion profiles in one single operation, thus eliminating costly secondary bending and joining processes. The Flextrude technology reduces manufacturing cost by 35% and lead time by 33%, compared with competing processes. The outcome from this project will create at least 115 skilled jobs and over £72 million revenue for our UK supply chain in 5 years after the project.